dymax bluewave 75 rev. 2.0 user guide · dymax bluewave® 75 user guide 5 equipment is designed to...

Dymax BlueWave® 75 Rev. 2.0 User Guide UV Light-Curing Spot Lamp ■ Instructions for Safe Use

■ Setup and Operation

■ Maintenance

■ Ordering Spare Parts and Accessories

2 Dymax BlueWave® 75 User Guide

About Dymax

UV/Visible light-curable adhesives. Systems for light curing, fluid dispensing, and fluid packaging.

Dymax manufactures industrial adhesives, light-curable adhesives, epoxy resins, cyanoacrylates, and activator-cured adhesives.

We also manufacture a complete line of manual fluid dispensing systems, automatic fluid dispensing systems, and light-curing

systems. Light-curing systems include LED light sources, spot, flood, and conveyor systems designed for compatibility and high

performance

with Dymax adhesives.

Dymax adhesives and light-curing systems optimize the speed of automated assembly, allow for 100% in-line inspection, and

increase throughput. System designs enable stand-alone configuration or integration into your existing assembly line.

Please note that most dispensing and curing system applications are unique. Dymax does not warrant the fitness of the product for

the intended application. Any warranty applicable to the product, its application and use is strictly limited to that contained in the

Dymax standard Conditions of Sale. Dymax recommends that any intended application be evaluated and tested by the user to insure

that desired performance criteria are satisfied. Dymax is willing to assist users in their performance testing and evaluation by offering

equipment trial rental and leasing programs to assist in such testing and evaluations. Data sheets are available for valve controllers

or pressure pots upon request.


Contents Introduction .................................................................................................................................................... 4

Where to Get Help .......................................................................................................................................................... 4

Safety .............................................................................................................................................................. 4 UV Light-Curing System Safety Considerations ............................................................................................................... 6

Product Overview ........................................................................................................................................... 8 Description of the BlueWave 75 ...................................................................................................................................... 8

Assembly and Setup ........................................................................................................................................ 9 Unpacking and Inspecting Your Shipment ....................................................................................................................... 9 Parts Included with the BlueWave 75 ............................................................................................................................. 9

Installation and System Interconnect ............................................................................................................ 10

Settings and Adjustments ............................................................................................................................. 11 Intensity Adjustment ..................................................................................................................................................... 11 Intensity Validation ....................................................................................................................................................... 12 Intensity Control ............................................................................................................................................................ 12 Setting the Cycle Duration ............................................................................................................................................. 12 Lamp Dual-Hour Meter.................................................................................................................................................. 13

System Operation ......................................................................................................................................... 14

Maintenance ................................................................................................................................................. 15 Lightguide Maintenance ................................................................................................................................................ 16 Fuse Replacement ......................................................................................................................................................... 15 Fan Filter Maintenance.................................................................................................................................................. 16 Bulb Replacement ......................................................................................................................................................... 16

Troubleshooting ............................................................................................................................................ 19

Frequently Asked Questions ......................................................................................................................... 20

Spare Parts and Accessories .......................................................................................................................... 22 Spare/Replacement Parts .............................................................................................................................................. 22 Options/Accessories ...................................................................................................................................................... 23

Specifications ................................................................................................................................................ 24 Specifications................................................................................................................................................................. 24

Definition of Terms ....................................................................................................................................... 25

Warranty ...................................................................................................................................................... 26 Replacement Bulb Warranty ......................................................................................................................................... 26

Index ............................................................................................................................................................. 27


Introduction The enclosed BlueWave 75 UV Light-Curing Spot Lamp System was developed and manufactured by the

Dymax team, driven by a desire to best serve your needs. Before shipping, your BlueWave 75 was

thoroughly checked and tested for trouble-free performance.

The proper setup and operation of this system will maximize safety and user-friendly performance,

providing optimum yield of your technological process.

Therefore, we encourage you to read, understand, and follow all safety and operating instructions and

recommendations compiled in this and other related manuals prior to setting up and operating this new

spot-lamp system or its individual components.

If you encounter a problem, have any questions, or would like to pass on your suggestions or

recommendations, please contact our Application Engineering or Customer Service Departments. Trained

Dymax professionals are standing by to serve you.

Par conséquent, nous vous encouragez a lire, comprend, et suivre tout sécurité et instructions

d’opération et conseillations rédiger dans cette et autre manuels établir un lien avant de mettre en place

et de faire marcher cette nouveau système de lampe de tache ou cette composants individuel.

Si vous rencontrez un problème, avait n’importe de questions, ou si vous voudrez de nous aider avec tes

suggestions ou conseillations, s’il vous plait contacte notre départements technique ou service client.

Dymax formé professionnels attendre à vous servir.

Where to Get Help

Additional resources are available to ensure a trouble-free experience with our products:

■ Detailed product information on www.dymax.com.

■ Customer Support and Applications Engineering teams are available by phone and email in Germany,

Monday through Friday, from 8:00 a.m. to 5:00 p.m. Central European Time. You can also email

Dymax Europe GmbH at [email protected]. Please see the back cover for worldwide contact

information.

■ Dymax adhesive Product Data Sheets (PDS) on our website

■ Material Safety Data Sheets (MSDS) provided with shipments of Dymax adhesives

Safety CAUTION! Always wear proper eye protection when working with this unit, which emits high-intensity ultraviolet and visible energy! Note: The rear of the unit also emits stray UV & Visible energy.

WARNING! Always observe safety requirements!

CAUTION! Risk of electrical shock if cover is removed!

CAUTION! Cover is warm to the touch when unit is in operation!

http://www.dymax.com/

mailto:[email protected]


Equipment is designed to be used properly setup, with components correctly connected and operated in

accordance with relevant instructions. The system’s design was developed to maximize operator safety

and minimize exposure to UV.

Safety Recommendations

Use the provided safety eyewear or an approved face shield for eye/face protection.

Long-sleeved shirts or a lab coat are recommended to protect arms and the use of UV opaque gloves

will protect the hands.

NOTE: The BlueWave 75 emits UVA and visible light. Never look directly into the lightguide entrance fitting or end of lightguide while the unit is on.

Sécurité PRÉ-CAUTION! Toujours faisez de l’usage des lunettes de protection ou protéger de visage marche près du devant d’élément!

AVERTISSEMENT! Remmarquez toujours besoin de sécurité!

PRÉ-CAUTION! Risque de décharge électrique quand le couvert est enlever!

PRÉ-CAUTION! Le couvert est chaud a le touche quand l’élément est en opération!

L’équipment ètre concu pour ètre utilisé correctement constituer, avec composants brancher

correctement, et marché en conformément avec instructions important. Le plan étais developer pour

render au maxime opérateur sécurité et minimiser expositon à ultraviolette.

Recommander de Sécurité

Emploi lunettes, ou un protéger de visage pour protection de ultraviolet pour protéger vous oeux.

Chemises à manche long, ou manteau de labo, sont recommander pour protéger les bras, et utilisation

de ultraviolette gants opague vais protéger les mains.

REMARQUER: Avec le filtre intérieur installé, l’onde bleu émettre lumière. Ne jamais regardez directement à la source de lumière pendant que l’élément est en opération.

Sicherheitshinweise ACHTUNG! Tragen Sie immer eine Sicherheitsbrille oder einen Gesichtsschutz, wenn Sie nahe an der UV Lichtquelle arbeiten. Die Rückseite des Gerätes emittiert gestreutes UV Licht!

WARNHINWEIS! Bitte beachten Sie immer die Sicherheitshinweise!

ACHTUNG! Gefahr eines Stromschlages bei geöffnetem Gehäuse!

ACHTUNG! Gehäuse erwärmt sich während des Betriebs: Vorsicht bei Berührung!


Dieses Gerät wurde so entwickelt, dass es nur vollständig, alle Komponenten korrekt miteinander

verbunden, in Übereinstimmung mit relevanten Instruktionen betrieben wird. Bei der Entwicklung wurde

weiterhin großen Wert auf die Benutzersicherheit und minimale UV Belastung gelegt.

Sicherheitshinweise

Tragen Sie immer die mitgelieferten Sicherheitsbrille oder speziellen Gesichtsschutz, der Ihre Augen

vor UV Licht schützt.

Wir empfehlen Langarm - Hemden oder einen Laborkittel zu tragen, um die Arme zu schützen. Für die

Hände empfehlen wir UV- geblockte Handschuhe.

BITTE BEACHTEN SIE: Durch den installierten inneren Filter strahlt die BlueWave 75 und sichtbares Licht aus. Schauen Sie deshalb niemals direkt in die Lichtquelle, wenn das Gerät angeschaltet ist.

UV Light-Curing System Safety Considerations

Dymax light-curing technology has been used successfully for over 30 years. The fast cure, one-

component nature of our curing technology has made it the process of choice for many manufacturers

requiring a “cure on demand” assembly process. There are four common questions/concerns related to

light-curing systems: UV exposure, high-temperature surfaces, ozone, and bright, visible light.

UV Exposure

Standard Dymax UV light-curing systems have been designed to primarily emit UVA light (Figure 1). UVA

light is generally considered the safest of the three UV ranges: UVA, UVB, and UVC. Although OSHA does

not currently regulate ultraviolet-light exposure in the workplace, the American Conference of

Governmental Industrial Hygienists (ACGIH) does recommend Threshold Limit Values (TLV‘s) for ultraviolet

light. The strictest interpretation of the TLV (over the UVA range) for workers’ eyes and skin is 1 mW/cm2

(intensity), continuous exposure. Unless workers are placing bare hands into the curing area, it is unusual

to exceed these limits. To put 1 mW/cm2 limit into perspective, cloudless summer days in Connecticut

regularly exceed 3 mW/cm2 of UVA light and which includes the more dangerous UVB light, primarily

responsible for sun tans, sun burns, and skin cancer.

The human eye cannot detect “pure” UV light, only visible light. A radiometer should be used to measure

stray UV light to confirm the safety of a UV-curing process. A workstation that exposes an operator to

more than 1 mW/cm2 of UVA continuously should be redesigned.

Figure 1. Spectrum of Light


Light-curing technology can be a regulatory compliant, “worker-friendly” manufacturing process when the

proper safety equipment and operator training is utilized. There are two ways to protect operators from

UV exposure: shield the operator and/or shield the source.

Shield the Operator

UV-Blocking Eye Protection – UV-blocking eye protection is recommended when operating UV-curing

systems. Both clear and tinted UV-blocking eye protection is available from Dymax.

UV-Blocking Skin Protection – Where the potential exists for UV exposure upon skin, opaque, UV-

blocking clothing, gloves, and full-face shields are recommended.

Shield the Source of UV Light

Any substrate that blocks UV light can be used as a shield to protect workers from stray UV light. The

following materials can be used to create simple shielding structures:

Sheet Metal – Aluminum, steel, stainless steel, etc. Sheet metal should be coated black or black anodized

to minimize reflection of UV and visible light toward operators.

Rigid Plastic Film – Transparent or translucent, UV-blocking plastics (typically polycarbonate or acrylic)

are commonly used to create shielding where some level of transparency is also desired.

Flexible Film – Translucent UV-blocking, flexible urethane films can be used to quickly create workstation

shielding. This UV-blocking, flexible urethane film is available from Dymax.

High-Temperature Surfaces

Surfaces exposed to high-intensity curing lights will rise in temperature. The intensity, distance, exposure

time, cooling fans, and the type/color of the surface can all affect the actual rise in surface temperature.

In some cases, exposed surfaces can reach temperatures capable of producing a burn or causing damage

to a substrate. In these cases, care must be taken to ensure either a more moderate surface temperature

or appropriate protection/training for operators.

Ozone

Standard Dymax bulbs (UVA type) generate an insignificant amount of UVC and therefore essentially no

ozone. Some UV light-curing systems, like those used to cure UV inks, emit primarily “shortwave” (UVB

and UVC) energy. Upon exposure to UVC energy (specifically <240 nm), oxygen molecules (O2) split into

oxygen atoms (O) and recombine with O2 to create ozone O3. The current, long-term ozone concentration

limit recommended by ACGIH, NIOSH, and OSHA is 0.1 ppm (0.2mg/m3).

Bright, Visible Light

The bright, visible light energy emitted by curing systems can cause eyestrain if proper eye protection or

shielding is not used. Tinted eye protection and/or opaque/tinted shielding can be utilized to address this

concern.

Summary

UV-light sources can be more “worker friendly” than many commonly accepted industrial processes,

provided the potential concerns are addressed. Both the lower working temperature and lack of spurious

frequency transmission that this system produces make it even more user friendly. Contact your Dymax

representative for information regarding the proper use of Dymax light-curing systems.


Product Overview Description of the BlueWave 75

The BlueWave 75 is a high-intensity, UV light-curing spot lamp used for the curing of adhesives, coatings, and potting materials. It emits UV light from a lightguide which can be hand-held for complete mobility, fixtured into position for repetitive operations, or integrated into automated equipment.

The unit consists of an anodized aluminum housing, containing an electronic power supply, circuit protection, a bulb/reflector assembly, an internal light filter, a thermostatically-controlled cooling fan, a lightguide mount, bulb and unit status indicator lights, a combination resettable and non-resettable hour-meter, and a shutter system. A thermal shutdown sensor is provided for internal temperature control of the unit. A cover-closed switch and lightguide-sensing switch add to the safety of the unit. Fan filters should be changed or cleaned frequently to prevent blockage and reduced ventilation airflow. Electric shutters are supplied with timed and manual shutter operating modes. The lightguide is separate and plugs into the lightguide entrance fitting on the front panel (the forward facing lightguide mount).

An intensity control feature allows operators to adjust output intensity during process validation and production. Users can now manually adjust intensity to compensate for bulb degradation and to maintain an optimized output or allow it to emit direct line of sight energy to unprotected personnel.

CAUTION: Once the lightguide is engaged there exists the possibility of light emitting if the unit is triggered. Never look directly into the lightguide.

A cooling fan is provided to keep the bulb housing and internal components of the power supply at the optimum operating temperature. The fan or exhaust opening must not have any restriction in their airflow path. The UV source is a 75-Watt short-arc bulb mounted in a reflector and pre-focused to provide optimum light output. The unit is rated for continuous operation.

The blue indicator light (located above the lightguide mount) lights when the bulb is operating. The power supply operates on line voltages between 100 and 240 VAC and frequency between 50 and 60 Hz.

If the bulb extinguishes due to a momentary power failure the unit must be turned off and allowed to cool 20 minutes before attempting to re-ignite the bulb. Arc-type bulbs are designed to (and prefer) to be run continuous. Repeated on/off cycling decreases bulb life and accelerates intensity degradation. It is good practice to leave the unit running for a full 8-10 hour shift and only turn the unit off if it will be off for more than a few hours or overnight.

Figure 2. BlueWave 75 Front Face Plate

Bulb Hour Meter Operation Mode

Lightguide Entrance Fitting

Intensity Adjustment Indicator LEDs Power Switch

Shutter Cycle Timer


Assembly and Setup

Unpacking and Inspecting Your Shipment

Depending upon your order, your BlueWave 75 will arrive in one or two boxes. Inspect the boxes for

damage and notify the shipper of box damage immediately.

Open each box and check for equipment damage. If parts are damaged, notify the shipper and submit a

claim for the damaged parts. Contact Dymax so that new parts can be shipped to you immediately.

Check that the parts included in your order match those listed below. If parts are missing, contact your

local Dymax representative or Dymax Customer Support to resolve the problem.

Parts Included with the BlueWave 75

■ BlueWave 75 Spot Curing Lamp (1)

■ BlueWave 75 Spot-Curing System User Guide (2)

■ UV Protection Goggles (3)

■ Power Cord; Style Dependent on Model Ordered (4)

40078 – 115V Standard North American Power Cord 40077 – Type G Power Cord 40183 – No Power Cord (Note: For European customers, the appropriate power cord will be added)

■ Tools - Hex Wrench (5) & Screw Driver (6)

■ Footswitch (7)

Figure 3. BlueWave 75 Unpacking Diagram

NOTE: Units are shipped with the Bulb/Reflector installed


Installation & System Interconnect 1. Connect the Power Cord to the back of unit and plug the other end into a grounded wall outlet.

2. Connect the Footswitch to the connection in the back of the unit. A Ground Stud is provided on the

back of the unit if additional grounding is desired.

Figure 4. Rear Cable Connections

3. Remove the protective end caps from the Lightguide (purchased separately). Visually inspect the two

ends to verify that no foreign material is present. If required, the ends of the Liquid-Filled Lightguide

can be cleaned with isopropyl alcohol to remove oils and debris. Attach the Lightguide by removing

the shipping cap covering the Lightguide Mount (Figure 5) and inserting the Lightguide. Lightly

tighten the setscrew on the Lightguide Mount to secure the Lightguide (Figure 6).

NOTE: Do not over tighten the setscrew as permanent and non-warranty damage will result.

Figure 5. Shipping Cap in Lightguide Mount

Figure 6. Lightguide Connection

4. Turn the Power Switch to the on position.

5. Allow the bulb to warm up (about 5 minutes). The unit is warmed-up when the blue Unit Ready LED

illuminates and two beeps sound. The Shutter will be inoperable until the warm-up is complete and a

Lightguide is installed.

Note: If the unit is coming on from an extreme cold condition (<0ºC), the system fan will turn on to initiate a warming cycle and the Unit Ready LED will pulse as ambient air (>2ºC) is being circulated

Power Cord

Ground Stud

Footswitch


through the unit. Once the internal temp is >2ºC, the bulb will ignite and the normal warm-up cycle will commence.

6. Operate the Shutter by pressing the Footswitch. With the Shutter Selector Switch in the manual

position, the Shutter operates directly from the Footswitch and will remain open as long as the switch

is depressed. In the timed position, the open duration of the Shutter is determined by the setting on

the electronic Shutter Timer. A momentary depression of the Footswitch will initiate the timed cycle

and the Shutter will remain open for the duration of the cycle (the counter will count down the time

until the Shutter closes).

7. With the Shutter open, adjust the Intensity Adjustment Screw as required to achieve the desired

output intensity. The output intensity can be measured using an ACCU-CAL™ 50 Radiometer or

equivalent.

CAUTION: This unit uses an arc bulb, not a filament bulb. Once ignited, the unit must be left on for a minimum of 10 minutes to vaporize elements in the bulb. If the unit is not left on for the required time, re-ignition of the bulb may be difficult or unreliable.

Note: The bulb must cool before it can be re-ignited. Turn the unit off and allow 20 minutes for it to cool down. If the bulb fails to ignite, refer to the “Troubleshooting” section of this manual. Bulb life is reduced each time the unit is switched on. Avoid repeated cycles that shorten bulb life by leaving the unit on through breaks.

Settings and Adjustments

Intensity Adjustment

A Dymax ACCU-CAL™ 50 Radiometer can be used to set and monitor the unit's intensity output. If the

BlueWave 75's output intensity needs adjustment, use the Intensity Adjustment Knob. This knob installs

into the Intensity Adjustment Screw (Figure 7) using the M2 screw included with the unit. A small

screwdriver (included) can also be used to adjust the intensity (Figure 8). If it is undesirable to allow the

operator easy access to the intensity adjustment, it is recommended that the Intensity Adjustment Knob

not be attached.

Turning the Intensity Adjustment Knob fully clockwise will provide full intensity out the Lightguide. As the

Intensity Adjustment Knob is turned counter-clockwise the intensity will slowly be reduced.

Figure 7. Intensity Adjustment Knob

Figure 8. Adjusting Intensity with a Screwdriver


Intensity Validation

Prior to production, Dymax advises customers to conduct testing to determine the time and intensity

required to fully cure their resin in their specific application. Typically, users validate by one of the

following methods:

Set Exposure Time, Determine Intensity: Users can specify a cure time and through empirical testing, determine the intensity required to achieve full cure. As with any manufacturing process, it is advisable to incorporate a safety factor.

Set Intensity, Determine Exposure Time: Users can specify intensity and through empirical testing, determine the exposure time required to achieve full cure. As with any manufacturing process, it is advisable to incorporate a safety factor.

Intensity Control

Process validation confirms a minimum acceptable intensity. Users can then choose to operate at full

intensity (using the excess intensity as an additional safety factor) or maintain a constant intensity through

periodic manual adjustments.

BlueWave 75 bulbs will typically vary less than 1% over eight hours of normal use and so daily or weekly

adjustments are adequate to maintain a tightly controlled process. A Change Bulb Indicator LED is

provided to alert the operator to check bulb operation or to change the bulb if required.

Setting the Cycle Duration

The Shutter Timer located on the front panel of the BlueWave 75 is factory set to the most common

operating mode and recommended operation of the Shutter Timer with the BlueWave 75. Some modes

available on this Shutter Timer may not operate correctly with the BlueWave 75 unit and have been

disabled.

The Shutter Timer has an LCD Display and Keypad. The LCD Display has a Reset Indicator, Key Protect

Indicator, Output Indicator, Preset Value, Set Value, and Timing Operation Indicator. Below is a brief

description of each display and location.

Figure 9. Shutter Timer

Timing Value

Set Value

Digital Increment 1-4

Press top half to

increment digit up

Digital Increment 1-4

Press bottom half to

increment digit down Reset Button

Reset Indicator

Key Protect

Output Indicator


■ RST [Reset Indicator] – This setting becomes active when the Shutter Timer is reset by pressing the

“RST” Button (Reset Button) on the lower left face of Shutter Timer.

■ K/P [Key Protect] – This setting is always lit as the function of the Shutter Timer is programmed at

the factory and locked before shipment.

■ OUT [Output Indicator] – This setting is displayed when the relay is switched on and is not displayed

when the relay is switched to off.

■ RST [Reset] Button – This button is located in the lower left corner of the Shutter Timer. Pressing

this button will reset the Shutter Timer.

■ Timing Value – This is a four-digit segmented display in the center of the Shutter Timer. It shows the

current status of time.

■ Set Value – This is a four-digit segmented display in lower right corner of the Shutter Timer. It shows

the set length of time.

In addition to the indicators, the Shutter Timer contains six buttons with their functions described as

follows:

■ MODE –Disabled at the factory and locked before shipment.

■ Reset Indicator (RST) – Used to cancel out of a timed cycle. If a cycle is initiated and counting down,

pressing this button will close the Shutter and reset the counter to the current preset.

■ Digit Increment 1-4: Pressing these buttons up or down will increment or decrement that digit by

one. The timer digits are formatted MM:SS for a maximum Shutter time of 99 minutes and 0.99

seconds. Consult Dymax for information on changing the format of this Timer.

To set the Shutter’s open duration, press the appropriate up/down button until the corresponding digit

increments in the set value. Pressing the key labeled 1 will increment the left most digit on the set value.

Pressing the key labeled 2 will increment the second digit of the set value and similar for digits 3 and 4.

The small grey buttons are rocker style so pressing the top half increments the digit up, while pressing the

bottom half will increment down. The Timer will increment from 9 back to 0. The Timer comes

programmed for a range of 00.01 seconds to 99.99 seconds. Contact Dymax for other time ranges and

functions.

To operate the Timer, select the Timer Operation Mode on the front panel (large rocker switch left of the

Shutter Timer). Program the correct time into the Timer and depress the Footswitch. The Shutter will

open and the preset value will begin to count backward. When the Timer reaches 00.00, it will reset to

the programmed value and the Shutter will close. The Timer can be stopped once started by pressing the

Reset Button on the lower left face of the Timer. If power is removed from unit, the Timer will reset to the

programmed value.

Lamp Dual-Hour Meter

The Lamp Dual-Hour Meter (Figure 10) provides the unit’s total hours of operation (top display), as

well as the bulb usage (bottom display). The total unit hour display continues to count hours of

operation on the unit and cannot be reset. The lower display reflects the number of hours on the

bulb.

Bulb hours should only be reset when a new bulb is installed. Instructions for bulb replacement are

found in this user guide and are also located on a label under the unit cover next to where the bulb is

located.


When the Lamp Hour Meter reaches 2,000 hours, the bulb will turn off and the Hour Meter will alternate

between “CHANGE BULB” and "2000.0". The unit will not operate until a new bulb is installed as described

in the Maintenance Section of this user guide.

WARNING: Operating a BlueWave 75 Lamp beyond 2,000 hours will result in a non-passive failure of the lamp! Do not reset the Lamp Hour Meter without replacing the bulb.

Figure 10. Lamp Dual-Hour Meter

System Operation

1. The BlueWave 75 will arrive almost fully assembled. Please refer to Installation and System

Interconnect for installation of the Lightguide, Power Cord, and Footswitch. The system should be

positioned in a dry location that does not obstruct airflow from the rear of the unit.

Note: Do not block the vents at the rear of the unit. Allow a minimum of 12" [150 mm] clearance from the back vents to the nearest obstructing surface.

2. Follow the procedures for connecting the Power Cord, Footswitch, Lightguide, and additional

Grounding Wire (if necessary).

3. Follow the steps to set the desired intensity and shutter cycle duration.

4. The Lightguide can be hand held, fixed over the curing area using an optional Lightguide Mounting

Stand (PN 39700), or fixtured using custom tooling. The UV and visible light emitted from a

Lightguide diverges. As a result, the intensity decreases and the curing area increases with distance

from the end of the Lightguide. Figure 11 shows this relationship for the 5-mm Liquid Lightguide.

Values given are for general reference; actual intensities can be measured using a Radiometer.

5. Apply the proper Dymax product for the application, fixture if necessary, and cure using the BlueWave

75.

Note: For additional information on light-curing systems, refer to Dymax LIT010 – Guide to Selecting and Using Dymax Light-Curing Systems and LIT008 – Comprehensive Guide to Dymax Light-Curing Technology.


Figure 11. Curing Area/Intensity VS. Distance using a 5-mm Lightguide

Maintenance The BlueWave 75 was designed to operate with minimum maintenance and following basic steps below

will assure continued top performance.

Fuse Replacement

The unit has two Fuses that are installed in the Power Receptacle. To remove the Fuses, unplug the unit

and remove the Fuse Holder with a small screwdriver (Figure 12). Remove the Fuses from the Fuse Holder

and install new Fuses. Replace the Fuse Holder into the Power Receptacle (Figure 14).

Figure 12. Power Receptacle

Figure 13. Fuse Holder

Figure 14. 4.0 Amp Fast-Acting Fuse (PN 37869)


Fan Filter Maintenance

The external Fan Filters should be inspected and

cleaned periodically to prevent dust buildup from

affecting airflow through the unit. Spare Fan

Filters are provided with each unit and with

replacement Bulbs. The Fan Filters are washable

and may be reused. Remove the Fan Filter by

removing the Snap-On Cover from the rear of

each Grill.

Figure 15. Fan Filter Replacement

Lightguide Maintenance

Clean the Lightguide ends monthly or as required. The ends of the Lightguide should be kept clean to

transmit as much energy as possible. Cured adhesive can be removed with a razor blade or isopropyl

alcohol (IPA). Avoid tight radius bends of the Lightguide since this will reduce output and may cause

permanent damage to the guide.

Bulb Replacement

1. Unplug the unit. Remove the top cover from the BlueWave 75 by loosening the four cover fasteners

(these are the four extended screws on the sides of the top cover).

2. Unplug the Bulb Connector and loosen the two knurled screws shown in Figure 16. Pivot the white

Bulb Clamp up and out of the way to allow removal of the Bulb.

Figure 16. Bulb Replacement Step 1-2

3. Gently tip the back end of the Bulb down to un-seat the top edge and remove the Bulb.

Screw

Screw

Bulb Clamp

Snap-On Grill Cover

Fan Filter PN 38659

Bulb Connector


Figure 17. Bulb Replacement Step 3

4. Using powder free gloves, unpack the new Bulb (PN 40205). Take care not to bend the Flat Electrode

in the center of the Bulb.

5. Orient the new Bulb so the Side Electrode Wire is positioned at the side of the housing that is open.

Carefully seat the bottom edge (Figure 18). The lower Retaining Spring Wire will exert resistance that

you will need to overcome as you seat the Bulb. With the lower edge seated, tip the top edge into the

upper seat. The Bulb will remain in place if properly installed.


6. Pivot the white Bulb Clamp in place and tighten the two knurled screws. Plug in the Bulb Connector

(Figure 19).


7. Replace the unit’s cover and tighten the four cover fasteners. Once the cover is secure, power up the

unit and using a small screw driver press the Reset Button located on the back of the unit. This will

Screw

Screw Bulb Connector

Side Wire (located “inward”)


reset the Bulb Hour Meter but not extinguish the Change Bulb Indicator Light. Cycle the system power

once to reset the Change Bulb Indicator Light.


Note: Fan Filters (included with replacement bulbs) MUST also be replaced during a bulb change.

8. Once the new Bulb is installed and operational, it is recommended that the intensity is set again (see

Settings and Adjustments Instructions).

Reset Button

Fan Filter


Troubleshooting WARNING! Only qualified maintenance personnel should attempt the following procedures.

AVERTISSEMENT! Seulement personnel d’entretien diplomé devrais essayer les procedures suivant.

Table 1. Troubleshooting Chart for BlueWave 75

Problem Possible Cause Testing Corrective Action

Bulb will not ignite

or

Change Bulb Light is on

Improper connections Visually inspect all input/output connections (i.e. Power Cord, Bulb).

Secure all connections.

Bulb is beyond useful life of 2,000 hours

Replace with a new Bulb/Reflector Assembly. Reset Bulb Hour Meter and re-test unit.

Replace Bulb/Reflector Assembly if required. Typical Bulb life is 2,000 hours.

Main line Fuse blown (nothing in unit operates)

Remove Fuse from Power Receptacle and check with an Ohmmeter.

Replace Fuse, if defective.

Low output intensity

or

System fails to cure adhesive in allotted time

Bulb beyond useful life

Use a Radiometer to measure output intensity (Dymax ACCU-CAL™ 50 or equivalent).

Replace Bulb/Reflector Assembly if beyond useful life.

Transmission loss in Lightguide too great

Compare Lightguide output against new Lightguide (or use the Dymax Lightguide Simulator) to determine transmission loss.

Inspect and clean guide ends, and eliminate tight bends.

Replace Lightguide.

Contaminants on Lightguide

Visually examine ends of Lightguide for contaminants.

Clean with isopropyl alcohol or equivalent. Heavy deposits on liquid Lightguides may be carefully removed using a razor blade. Replace the Lightguide if it cannot be cleaned.

Bulb/Reflector Assembly not installed properly

Visually check to make sure the Bulb/Reflector Assembly is seated flush in the Bulb Mount Assembly (any error in installation could cause a low output)

Properly install Bulb/Reflector Assembly, see page 17.


Frequently Asked Questions

Q.) My BlueWave 75 will not turn on.

■ Check the power cord connection.

■ Check the Fuses located where the Power Cord plugs into the unit.

■ If a tone is heard, the Cover Interlock Sensor may not be closed. Verify that the cover is properly

closed and that the four side securing screws are tightened. Remove the cover and verify nothing is

preventing it from fully seating on the unit.

Q.) The blue lens on the front panel does not light.

■ This signifies the Bulb has not ignited. Check that the power cord and Bulb connections are secure.

Q.) The Bulb will not ignite, it only “flickers”.

■ Replace the Bulb. Excessive power cycling will shorten the life expectancy of the Bulb. This is an arc,

not filament Bulb. Once ignited, it must be left on for a minimum of 10 minutes to vaporize elements

in the Bulb. If not, the Bulb may be difficult to re-ignite.

Q.) I installed a new Bulb, and it still will not ignite.

■ The BlueWave 75 has a safety shutdown feature at 2,000 hours. If the equipment has reached the

safety shutdown point, "CHANGE BULB" and "2000.0" will alternate on the Hour Meter and the Bulb

will not light. When this happens, the BlueWave 75 will no longer supply an ignition voltage until a

new Bulb is installed and the Reset Switch is pressed on the back of the equipment. The power must

be on for this reset to be performed. The Reset Switch should always be pressed whenever a new

Bulb is installed and a Bulb should never be operated after it reaches the 2,000 hour life expectancy.

■ Check and make sure the Bulb Connector is fully seated into the Igniter.

Q.) Why do I have low intensity, even with a new Bulb?

■ Standard BlueWave 75 units have an Optical Filter installed, which filters the energy before it reaches

the Lightguide. The intensity may be decreased if the light that passes through the Filter is restricted

by dust and debris accumulated on the Filter surfaces.

■ The intensity is being checked too early. The 75W Bulb will not reach full intensity until at least five

minutes after initial power up.

■ The Lightguide may not be fully seated into the Lightguide Mount.

■ The end of the Lightguide may have a build-up of adhesive or outgassing residue. Carefully remove

with isopropyl alcohol or a razor blade for heavier deposits.

■ The condition of the Lightguide will also affect the intensity. All Lightguides degrade with time, but

intensity will also drop if the Lightguide is bent or kinked. The intensity reading from the Lightguide

should be compared to the intensity reading from a Lightguide Simulator to determine the efficiency.


■ The Bulb is not installed correctly. Bulb orientation is vital during the installation of the Bulb. Refer to

the Bulb installation instructions supplied with all new 75W Bulbs for the proper installation

procedure.

Q.) My Footswitch is not operating.

■ Check the connection of the Footswitch into the unit. Check that the Lightguide is fully installed and

that the “Lightguide Seated” indicating light is on.

Q.) What causes my Shutter to hesitate to open or close?

■ Maintaining clean equipment and a clean working environment will help prevent the build up of dust

and other debris from collecting on the mechanical parts of the BlueWave 75. Debris that settles in

the piston well (Adjustment Screw) can hinder the movement of the Shutter Solenoid Piston.

■ Shutter alignment to Reflector Mount incorrect.

■ The Shutter is a mechanical part which may wear after extended use.

■ The alignment of the Shutter to the Bulb Mount Assembly is incorrect.

Q.) Why does my BlueWave 75 seem to run very hot?

■ Replace the Fan Filter Media on the Exhaust Fan and vent located in the back of the equipment. This

is your first line of defense against airborne dust and debris. This Fan Filter Media is supplied with

new Bulbs and should be changed regularly.

■ Ideal operation of this equipment suggests at least 12" of clearance behind the unit for proper

ventilation. Confirm that the Intake Fan is not feeding from the exhaust of other equipment.

■ Confirm that the cooling fan is operating.

■ The unit may already be full of dust and debris and over heating the internal electronics.


Spare Parts and Accessories

Spare/Replacement Parts

Item Part Number

Fan Spare Parts

Fan Filter and Holder 38587

Fan Filter Media 38659

Fan 24 VDC 40204

Fuses

Fuses: F4.0 Amp 37869

Misc

Bulb/Reflector Assembly 40205

Clip, Reflector Upper (Teflon) 38548

Clip, Spring, Lower 39609

Feet (Rubber Bumper) 38572

Filter, Dual Fuse IEC AC Inlet 37178

Filter, Bandpass 35986

Footswitch 40402

Harness to Hour Meter 40728

Hour Meter (unit serial #s 5121800 and higher) 40730

Power Supply, 75W Assembly 40089

Shutter Guide 40224

Spring, Solenoid Plunger 40309

Shutter, Tear-Drop, SS 40313

Lightguide and Lamp Mount Assembly 40054

Switch, Manual Timer 36654

Switch, Power 36288

Timer, Digital 36287

PCB Temp Sensor 40099

Shield, Temp. Sensor 40419


Options/Accessories

Item Part Number

Cases

BlueWave Case with Foam 38679

Lightguides & Accessories

Liquid-D Lightguide, 5 mm X 1 Meter 5720

Liquid-D Lightguide, 5 mm X 1.5 Meter 5721

Liquid-D Lightguide, 8 mm X 1 Meter 5722

Liquid-D 2-Pole Lightguide, 3 mm X 1 Meter 38476



Fiber Optic 2-Pole Lightguide, 3 mm x 1 Meter 39783



Lightguide Simulator 38408

Lightguide Mounting Stand 39700

Additional liquid and fiber optic single- and multi-pole lightguide configurations are available. Contact Dymax for assistance.

Contact Dymax

Radiometers

Dymax ACCU-CAL™ 50 Radiometer (Spot Model) 39560

Figure 21. Bulb Assembly Part Numbers

40309

40224

40099

40419

40224

38548

39609


Specifications

Specifications

Property Specification

Part Number

PN 40078 North American Version (with 115V standard plug)

PN 40077 Asian Version (Type G plug)

PN 40183** Unit with no power cord

Intensities* Total (280-450 nm) 19+ W/cm2

Visible (400-450 nm) 9+ W/cm2

UVA* (320-395 nm) 9+ W/cm

2

UVB (280-320 nm) 1.5+ W/cm2

Power Requirements 100-240 VAC, 50/60 Hz, 1.0 Amps

Power Supply Solid State, 75 Watt

Bulb 75 Watt arc bulb (included)

Reflector Elliptical; glass with diachronic coating to reflect UV and minimize IR

Shutter Timer Digital LED timer up to 99.99 seconds; manual or timed shutter

Shutter Activation Footswitch

Cooling Filtered, thermally-controlled single fan configuration

Operating Conditions Temperature range 2-38°C, humidity limit – non-condensing

Hour Meter Digital LCD; Total unit operating hours (non re-settable) Total Bulb hours (re-settable)

Housing Dimensions 12" x 12.25" x 6.5" (30.5 cm x 31.1cm x 16.5 cm)

Weight 14 lbs. (6.0 kg)

System Warranty 1 year from date of purchase

Bulb Warranty 2,000 hours (no intensity warranty, only bulb ignition)

Replacement Bulb PN 40205

* Measured with an ACCU-CAL™ 50 radiometer using a lightguide simulator and standard internal “Cool Blue” filter.

** Contains the appropriate power cord for Europe


Definition of Terms Bulb - Light source generating ultraviolet, visible, and infrared radiant energy from burning matter

stimulated by electrical power conditioned by a proper power supply which is an integral part of a Lamp. A

light source is usually placed into a Reflector (of various geometry) to increase light source efficiency by

collecting and directing radiant energy of selected spectra (for a given curing process).

Intensity - a measure of energy over the unit of surface area (measured in W/cm2 or mW/cm

2). This

measure is also referred to as “irradiance”.

Brightness, also known as Luminance - description of energy in the visible region of the spectrum

(approxi-mately from 400 to 700 nm) and recorded in photometric units. “Intensity” (see below) of visible

light energy is called Luminance.

Luminance - luminous flux (energy of visible light) incident per unit area, and measured in Lx (lux) or

Lumen/cm2.

Ultraviolet (UV) - The invisible region of the spectrum just beyond the violet end of the visible region.

Wavelength ranges in general from 1.0 to 400 nm. Dymax bulbs (burners) do not radiate energy in deep

ultraviolet; there are very minute amounts below 220 nm and practically nothing can be sensed below 200

nm. This is due to the use of an ozone-blocking quartz-bulb envelope (See Ozone).

Ultraviolet A (UV-A) - UV of long wavelength from within approximately 400 to 320 nm of the

spectral band (4000 to 3200).

Ultraviolet B (UV-B) - UV of medium wavelength from within approximately 320 to 280 nm.

Ultraviolet C (UV-C) - UV of short wavelength below 280 nm (we say from 280 to 200 nm) – a large

amount of this energy is present in the sunlight.

Visible - Light that can be seen 400-700 nm.

Dose - is irradiance integrated over time, or Irradiance (W/cm2) x Time (s) = Dose (Joules/cm

2). Note:

Watt is the power that gives rise to the production of energy at the rate of 1-joule (J) per second (s).

Ozone - oxidizing agent (O3) produced by the action of Ultraviolet radiant energy (below 185 nm) or

electrical corona discharge of oxygen on air.

OSHA 1910.145: “Regulation of Accident prevention Signs and Tags” defines the following headers as:

■ Warning – is used when there is a hazardous situation that has some probability of severe injury.

■ Caution - is used to indicate a hazardous situation that may result in minor or moderate injury.

■ Notice - is used to convey a message related directly or indirectly to the safety of personnel, or

protection of property.

OSHA 1910.145: “Regulation de la prevention d’accident Signes et Étiquettes” défin les têtes comme:

Avertissement - est utilisser quand il ya un situation hasardeux qu’il avais de probalilité de se blesser

sévère.

Pre-Caution - est user pour indiquer un situation hasardeux qu’il peut être en consequence en

minueur ou modére blessure.

Attention - est user pour communiquer un message lié directement ou indirectement à la sécurité

de personnel, ou protection de proprieté.


Warranty

From date of purchase, Dymax Corporation offers a one-year warranty against defects in material and

workmanship on all system components with proof of purchase and purchase date. Unauthorized repair,

modification, or improper use of equipment may void your warranty benefits. The use of aftermarket

replacement parts not supplied or approved by Dymax Corporation, will void any effective warranties and

may result in damage to the equipment.

Replacement Bulb Warranty

If the bulb fails to ignite during the warranty period of 2,000 hours and all Bulb History Cards for a specific

BlueWave® have been returned to Dymax, the bulb will be replaced under warranty.

IMPORTANT NOTE: DYMAX CORPORATION RESERVES THE RIGHT TO INVALIDATE ANY WARRANTIES,

EXPRESSED OR IMPLIED, DUE TO ANY REPAIRS PERFORMED OR ATTEMPTED ON DYMAX EQUIPMENT

WITHOUT WRITTEN AUTHORIZATION FROM DYMAX. THOSE CORRECTIVE ACTIONS LISTED ABOVE ARE

LIMITED TO THIS AUTHORIZATION.


Index Assembly and Setup, 9

Bulb Replacement, 16

Definition of Terms, 25

Digit Increment, 13

Frequently Asked Questions, 20

Glossary, 25

Help, 4

Installation, 10

Interconnect, 10

Key Protect, 13

Lamp Dual Hour Meter, 14

Maintenance, 15 Fan Filter Maintenance, 16 Fuse Replacement, 15 Lightguide Maintenance, 16

Mode, 13

Operation, 14

Optional Equipment, 23

Output Indicator, 13

Parts Included, 9

Product Overview, 8

Reset Button, 13

Reset Indicator, 13

Safety, 4

Sécurité, 5

Set Value, 13

Settings and Adjustments, 11 Intensity Adjustment, 11 Intensity Control, 12 Intensity Validation, 12 Lamp Dual Hour Meter, 14 Setting the Cycle Duration, 12

Shutter Timer, 12

Sicherheitshinweise, 5

Spare Parts and Accessories, 22

Specifications, 24

Support, 4

Terms, 25

Timing Value, 13

Troubleshooting, 19

Unpacking, 9

UV Light-Curing System Safety Considerations, 6 Bright, Visible Light, 7 High-Temperature Surfaces, 7 Ozone, 7 UV Exposure, 6

Warranty Replacement Bulb Warranty, 26

Warranty General Warranty, 26

© 2012 Dymax Corporation. All rights reserved. All trademarks in this guide, except where noted, are the property of, or used under license by Dymax Corporation, U.S.A.

The data contained in this bulletin is of a general nature and is based on laboratory test conditions. Dymax Europe GmbH does not warrant the data contained in this bulletin. Any warranty applicable to products, its application and use is strictly limited to that contained in Dymax Europe GmbH’s General Terms and Conditions of Sale published on our homepage http://www.dymax.com/de/pdf/dymax_europe_general_terms_and_conditions_of_sale.pdf. Dymax Europe GmbH does not assume any responsibility for test or performance results obtained by users. It is the user’s responsibility to determine the suitability for the product application and purposes and the suitability for use in the user’s intended manufacturing apparatus and methods. The user should adopt such precautions and use guidelines as may be reasonably advisable or necessary for the protection of property and persons. Nothing in this bulletin shall act as a representation that the product use or application will not infringe a patent owned by someone other than Dymax Corporation or act as a grant of license under any Dymax Corporation Patent. Dymax Europe GmbH recommends that each user adequately test its proposed use and application of the products before actual repetitive use, using the data contained in this bulletin as a general guide. PN40153 MAN016EU 12/17/2012

Dymax Corporation 860.482.1010 [email protected] www.dymax.com

Dymax Oligomers &Coatings 860.626.7006 oligomers&[email protected] www.dymax-oc.com

Dymax Europe GmbH +49 (0) 611.962.7900 [email protected] www.dymax.de

Dymax UV Adhesives & Equipment (Shenzhen) Co Ltd +86.755.83485759 [email protected] www.dymax.com.cn

Dymax UV Adhesives & Equipment (Shanghai) Co Ltd +86.21.37285759 [email protected] www.dymax.com.cn

Dymax Asia (H.K.) Limited +852.2460.7038 [email protected] www.dymax.com.cn

Dymax Korea LLC 82.2.784.3434 [email protected] www.dymax.co.kr

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